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CN-121988830-A - Penetration welding control method and system for steel bar truss anchoring pile

CN121988830ACN 121988830 ACN121988830 ACN 121988830ACN-121988830-A

Abstract

The invention relates to the technical field of welding control and discloses a penetration welding control method and a penetration welding control system for a steel bar truss anchoring pile, wherein the method comprises the steps of obtaining welding characteristic parameters and carrying out structural coding to obtain characteristic vectors; the method comprises the steps of determining an initial process window and control parameters based on the vector, configuring a state boundary threshold initial value of a penetration evaluation model, carrying out closed-loop adjustment by taking a time window as a period in welding, collecting data in real time, extracting process characteristic quantity, inputting the model to obtain penetration state quantity and trend quantity, updating the state boundary threshold value on line based on the deviation of the state quantity and criteria, and adjusting welding current, voltage, speed and swing parameters in a cooperative manner according to the state quantity and the trend quantity. According to the invention, through the structural characterization of the object characteristics, the online self-adaptive updating of the model judgment threshold value and the multi-parameter linkage adjustment, the real-time assessment and the closed-loop control of the penetration state are realized, and the problems of poor penetration stability and insufficient mass production consistency under the condition fluctuation are solved.

Inventors

  • LIU ZEFEI

Assignees

  • 廊坊腾乾节能科技有限公司

Dates

Publication Date
20260508
Application Date
20260209

Claims (10)

  1. 1. The penetration welding control method for the steel bar truss anchoring pile is characterized by comprising the following steps of: Obtaining welding characteristic parameters of an object to be welded, and carrying out structural coding treatment on the welding characteristic parameters to obtain a welding object characteristic vector; determining a welding initial process window through a process window generation rule based on the welding object feature vector, and mapping to obtain initial welding control parameters based on the welding initial process window; Performing welding according to the initial welding control parameters, and performing closed-loop adjustment in a cyclic manner by taking a preset time window as a period in the welding process, wherein the closed-loop adjustment comprises the steps of collecting welding process parameters and sensor information in real time in a current time window, and preprocessing the welding process parameters and the sensor information to obtain process characteristic quantities; Inputting the process characteristic quantity into the penetration evaluation model to obtain penetration evaluation output, generating penetration state quantity based on the penetration evaluation output and the state boundary threshold value, and generating penetration trend quantity based on the penetration state quantity of a plurality of continuous time windows; Obtaining an online deviation term based on the penetration state quantity and a preset penetration criterion, generating a threshold correction quantity according to the online deviation term, and updating the state boundary threshold based on the threshold correction quantity to serve as a judgment basis for generating the penetration state quantity in a next time window; And determining a parameter adjustment amount based on the penetration state amount and the penetration trend amount, and applying the parameter adjustment amount to welding current, welding voltage, welding speed and swing parameters for adjustment.
  2. 2. The penetration welding control method for steel bar truss anchor piles according to claim 1, wherein the method for obtaining welding characteristic parameters of an object to be welded, when performing structural coding processing on the welding characteristic parameters to obtain a welding object characteristic vector, comprises the following steps: carrying out field organization on the welding characteristic parameters, establishing a corresponding relation between the fields and the parameter types, and determining the value taking fields of the fields; Performing scale unification processing on the continuous value fields, and performing coding mapping processing on the discrete value fields to obtain field level coding results; Combining the field-level encoding results according to a field sequence to form a welding object feature vector; When the welding characteristic parameters have missing fields, generating substitution representation for the missing fields according to a missing processing rule, and writing the welding object characteristic vector, wherein the missing processing rule comprises the steps of judging the missing type of the missing fields, generating an inferred value representation under the condition that missing can be inferred, generating a statistical representative value representation under the condition that missing can be statistically complemented, generating a reference value representation under the condition that missing can not be complemented, and generating a missing identification for the missing fields and writing the welding object characteristic vector.
  3. 3. The penetration welding control method of a steel bar truss anchor pile according to claim 2, wherein when determining a welding initial process window by a process window generation rule based on the welding object feature vector, comprising: establishing a process window representation, wherein the process window representation is composed of an allowable value range of welding control parameters and corresponds to a state boundary threshold initial value of a penetration evaluation model; inputting the welding object feature vector into a process window generation rule to obtain a candidate process window, wherein the process window generation rule comprises one of a rule mapping mode and a data driving mode; Performing an availability check on the candidate process window, the availability check including a heat input boundary check and a shaping constraint check; And when the candidate process window does not pass the availability check, executing boundary correction on the candidate process window, wherein the boundary correction comprises convergence adjustment on an overrun boundary and consistency processing on collision between boundaries, so as to obtain the welding initial process window.
  4. 4. A penetration welding control method for a steel bar truss anchor pile as recited in claim 3, wherein when obtaining initial welding control parameters based on the welding initial process window map, comprising: representing the welding initial process window as a welding current range, a welding voltage range, a welding speed range and a swinging parameter range; Determining a welding current initial value, a welding voltage initial value, a welding speed initial value and a swing parameter initial value in the welding current range, the welding voltage range, the welding speed range and the swing parameter range respectively based on a parameter selection criterion; Performing combined consistency verification on the initial welding current value, the initial welding voltage value, the initial welding speed value and the initial swing parameter value; and when the combined consistency check fails, carrying out boundary rollback and reselection on the welding current initial value, the welding voltage initial value, the welding speed initial value and the swing parameter initial value, and outputting the initial welding control parameter.
  5. 5. The penetration welding control method for a steel bar truss anchor pile according to claim 4, wherein when determining a state boundary threshold initial value for a penetration evaluation model established based on historical welding data based on the welding object feature vector, comprising: acquiring historical welding data and constructing a training sample set, wherein the historical welding data comprises welding process parameters, sensor information and a post-welding inspection result corresponding to the historical welding data; sample alignment and sample cleaning are carried out on the training sample set, training input features are extracted, model training is carried out on the training input features based on the post-welding test results, model parameters are obtained, and the penetration evaluation model is established; Acquiring a threshold configuration set corresponding to the penetration evaluation model, wherein each threshold configuration in the threshold configuration set is stored in association with an object feature description, and the object feature description comprises a type field and a key feature range field; analyzing the welding object feature vector into a type field and a key feature component, and screening the threshold configuration set according to the type field to obtain a candidate threshold configuration set; sorting the candidate threshold configuration sets according to the matching degree between the key feature components and the key feature range fields, disambiguating according to the historical sample coverage index and the data consistency index when the sorting results are parallel, and determining target threshold configuration; acquiring a threshold sensitivity description, wherein the threshold sensitivity description comprises a corresponding relation between key feature component changes and state boundary threshold changes; Generating a threshold correction amount according to the deviation direction and the deviation amplitude between the key feature component and the key feature range field, and applying a clipping constraint to the threshold correction amount; And applying the threshold correction amount to a state boundary threshold value in the target threshold configuration to obtain an initial value of the state boundary threshold value.
  6. 6. The penetration welding control method for steel bar truss anchor piles according to claim 5, wherein the preprocessing of the welding process parameters and the sensor information in the current time window to obtain the process characteristic values comprises: time-aligning the welding process parameters and the sensor information, the time-aligning including performing resampling alignment of the multi-sample rate data to a same time reference; carrying out event segmentation on the current time window according to the change characteristics of the welding process parameters to obtain paragraph marks at least comprising an arc guiding section, a stable welding section and an arc receiving section; Performing quality gating processing on the data after time alignment, wherein the quality gating processing comprises the steps of identifying saturation, frame loss, abrupt jump and continuous distortion, performing rejection or substitution on the identified data, and generating a data credibility identifier corresponding to each paragraph identifier; performing baseline drift compensation on the time-aligned data, the baseline drift compensation including zero correction or amplitude normalization of the welding process parameters and the sensor information based on paragraph identification extraction baseline segments; and extracting statistical features and variation features corresponding to the heat input characterization, the arc stability characterization and the molten pool thermal state characterization in a stable welding section, and combining the statistical features, the variation features and the data credibility mark to obtain the process feature quantity.
  7. 7. The penetration welding control method of a steel bar truss anchor pile according to claim 6, wherein when the process characteristic quantity is input into the penetration evaluation model to obtain penetration evaluation output to generate penetration state quantity, the method comprises the steps of: Outputting a penetration evaluation output by the penetration evaluation model, wherein the penetration evaluation output comprises a penetration score amount and a scoring confidence; Acquiring the state boundary threshold, wherein the state boundary threshold comprises a first boundary threshold and a second boundary threshold; Determining a penetration state category according to the relation between the penetration evaluation amount and the first boundary threshold value and the second boundary threshold value, wherein the penetration state category comprises a penetration insufficient state, a penetration qualified state and an overheat risk state; and carrying out consistency check on the penetration state type based on the scoring confidence, and executing maintenance or rollback processing on the penetration state type when the consistency check is not satisfied, so as to obtain the penetration state quantity.
  8. 8. The penetration welding control method of a steel bar truss anchor pile according to claim 7, wherein when generating a penetration trend amount based on the penetration state amounts of consecutive time windows, comprising: Forming state sequences according to time sequence of penetration state quantities corresponding to each time window, and endowing corresponding confidence weights for each penetration state quantity in the state sequences; Executing trend distinguishing processing on the state sequence, wherein the trend distinguishing processing comprises the step of carrying out smoothing processing on the state sequence to identify a state transition direction; Determining a lack of penetration trend when the state transition direction transitions from a penetration qualified state to a lack of penetration state or is maintained in the lack of penetration state; determining an overheat trend when the state transition direction is transited from the penetration qualified state to the overheat risk state or is maintained in the overheat risk state; When the state sequence is maintained in a penetration qualified state or the migration between a penetration insufficient state and an overheat risk state does not reach a migration judgment condition, determining a penetration qualified trend; And taking any one of the insufficient penetration trend, the overheat trend and the penetration qualified trend as the penetration trend quantity.
  9. 9. The penetration welding control method of a steel bar truss anchor pile according to claim 8, wherein obtaining an online deviation term based on the penetration state quantity and a preset penetration criterion, generating a threshold correction amount according to the online deviation term, and updating the state boundary threshold based on the threshold correction amount as a basis for determining the penetration state quantity in a next time window, comprises: determining a target state interval according to the penetration criterion, and comparing the penetration state quantity of the current time window with the target state interval to obtain an online deviation item, wherein the online deviation item comprises a deviation direction mark and a deviation amplitude mark; Determining a threshold correction direction according to the deviation direction mark, determining a threshold correction amplitude according to the deviation amplitude mark, and generating a threshold correction amount; Applying the threshold correction to a first boundary threshold value when the penetration state quantity corresponds to a penetration insufficient state, applying the threshold correction to a second boundary threshold value when the penetration state quantity corresponds to an overheat risk state, and keeping the first boundary threshold value and the second boundary threshold value unchanged when the penetration state quantity corresponds to a penetration qualified state; Applying clipping constraint and update rate constraint to the threshold correction amount, performing consistency check on a threshold correction direction, and performing holding or rollback on the threshold correction amount when the consistency check is not satisfied; Applying the constrained threshold correction to the state boundary threshold to obtain an updated state boundary threshold; and generating the penetration state quantity based on the updated state boundary threshold value in the next time window.
  10. 10. A penetration welding control system for a steel bar truss anchor pile for realizing the penetration welding control method for a steel bar truss anchor pile according to any one of claims 1 to 9, comprising: The welding object coding module is configured to acquire welding characteristic parameters of an object to be welded, and perform structural coding processing on the welding characteristic parameters to obtain a welding object characteristic vector; The initial process configuration module is configured to determine a welding initial process window through a process window generation rule based on the welding object feature vector, obtain initial welding control parameters based on the welding initial process window map, and determine a state boundary threshold initial value based on the welding object feature vector for a penetration evaluation model established based on historical welding data; The window acquisition processing module is configured to perform welding according to the initial welding control parameters, and perform closed-loop adjustment in a cyclic manner by taking a preset time window as a period in the welding process, wherein the closed-loop adjustment comprises the steps of acquiring welding process parameters and sensor information in real time in a current time window, and preprocessing the welding process parameters and the sensor information to obtain process characteristic quantities; The penetration evaluation generation module is configured to input the process characteristic quantity into the penetration evaluation model to obtain penetration evaluation output, generate penetration state quantity based on the penetration evaluation output and the state boundary threshold value, and generate penetration trend quantity based on the penetration state quantity of a plurality of continuous time windows; The threshold correction module is configured to obtain an online deviation item based on the penetration state quantity and a preset penetration criterion, generate a threshold correction quantity according to the online deviation item, update the state boundary threshold based on the threshold correction quantity and serve as a judgment basis for generating the penetration state quantity in the next time window; And the multi-parameter adjusting module is configured to determine a parameter adjusting quantity based on the penetration state quantity and the penetration trend quantity, and apply the parameter adjusting quantity to welding current, welding voltage, welding speed and swinging parameters for adjustment.

Description

Penetration welding control method and system for steel bar truss anchoring pile Technical Field The invention relates to the technical field of welding control, in particular to a penetration welding control method and system for a steel bar truss anchoring pile. Background The steel bar truss anchoring pile is used for bearing and force transmission connection in engineering scenes such as an assembled foundation, foundation pit support and temporary support. The steel bar truss is connected with the pile body base material in a welding mode, and the pile body base material can be a steel pipe or a steel plate rolled piece and the like. The connecting part bears tension, shearing and repeated load in the use process, and the fusion continuity and penetration stability of the weld root have important influence on the connection reliability and the consistency of batch manufacturing. In the existing production, the welding of the steel bar truss and the pile body parent metal mostly adopts a fixed parameter or manual experience parameter adjustment mode based on a process card. The current, voltage, welding speed and swing parameters are usually selected according to the nominal size before welding, and the manual observation or spot check result is used as the quality judgment basis in the welding process. The wall thickness difference, the fluctuation of the assembly clearance and the welding posture change exist between the steel bar truss and the pile body, the welding heat input distribution and the molten pool behavior fluctuate along with the working condition change, and meanwhile, the surface state differences of zinc coating or coating residues, local oxidation, greasy dirt and the like possibly exist in the area to be welded, and the heat dissipation condition change can be caused by the contact state of the clamp and the heat dissipation path change. The above factors make it difficult to cover all working conditions with fixed parameters, which is easy to cause the defects of unfused root, unstable penetration or local burning-through, slag inclusion, air hole aggregation and the like, and meanwhile, the dispersion of weld joint forming and heat affected zone deformation in mass production is increased. In order to reduce the defect risk, part of schemes introduce welding process monitoring or post-welding detection, such as collecting current and voltage waveforms, arc light signals or temperature signals for process judgment, or adopting modes of flaw detection, open-section spot check and the like for quality confirmation after welding. However, the process monitoring is stopped at a threshold value for alarming or offline interpretation, and a real-time assessment and feedback mechanism for the penetration state and penetration trend is lacking; the judging threshold is usually fixed, misjudgment or judging hysteresis is easy to occur when the wall thickness difference, the gap fluctuation, the surface residue and the heat dissipation condition change, the welding parameter adjustment is mostly single parameter or manual intervention, synchronous linkage adjustment on current, voltage, welding speed and swinging parameters is difficult to form, meanwhile, the structural characterization of the difference of welding objects in the existing scheme is insufficient, the specific configuration of an initial process window and model criteria is difficult to complete before welding, and the consistency of control strategies among different piles is insufficient. Disclosure of Invention In view of the above, the invention provides a penetration welding control method and a penetration welding control system for a steel bar truss anchoring pile, which aim to solve the problem that in the prior art, the penetration state and trend are difficult to accurately evaluate in real time under the condition of fluctuation of working conditions, and closed-loop linkage adjustment is implemented according to the penetration state and trend, so that the fusion continuity and penetration stability of the root part of a steel bar truss and pile body connecting weld joint are difficult to be consistent in batch manufacturing. In one aspect, the invention provides a penetration welding control method for a steel bar truss anchoring pile, which comprises the following steps: Obtaining welding characteristic parameters of an object to be welded, and carrying out structural coding treatment on the welding characteristic parameters to obtain a welding object characteristic vector; determining a welding initial process window through a process window generation rule based on the welding object feature vector, and mapping to obtain initial welding control parameters based on the welding initial process window; Performing welding according to the initial welding control parameters, and performing closed-loop adjustment in a cyclic manner by taking a preset time window as a period in the welding process, wherein the closed